Method and apparatus for fiber collection



June 21, 1,955 E. H. NovoTNY ETAI- METHoD ANDAPPARATUS FOR FIBER COLLECTION `Filed sept. 24, 1949 o fofof s .....QYA

2,711,381 METHOD AND APPARATUS FOR COLLECTION t Edison H. Novotny, Monmouth Junction, and Lee'M. Hedges, Somerville, N.V J.,l'assgnors to Johns-Manville FIBER Corporation, New York, N. Y., a corporation ofNe`w York` Application September Z4, 1949, Serial NO.' 117,559

13 claims. y (cl. 154-401)V Y tively fragile, brittle fbersgsuch as mineral woolfibers,V but is `also suitable for use with mixtures ofksuch fibers,

and other fibers, or with other'bers alone.

` vention andfforcarryingoutthemethod thereof; Y

` tion,ft J`Perrn'it the movement offair'Vv therethrough? 1 suctionvbox 118 Yis, located 'below the upper reach ofthe Y ,L I

A principal object of the-invention'istthet-provisionvof a method and apparatus for-"the collection oftiibers jin interfelted relationship which -vvill KFproduce a lo'w-/clensity,

lofty and uniform felt.

Another object ofthe invention is the provisionof such method and apparatus inzwhichfthe fibersA arecollected from an air suspension thereof'in'ia zone of Isubcompressed or disturbed after feltforrnation.'

30 stantially zero static pressure, wherebyzthel fibers arejnotv i A further object of the invention is the provision lof a method andapparatus-of the kind'referred to' including a fiber opening' device'which-,dischargesttheopened bers 1 ability of the uncured felt. `Also, the'method provides*v p for theV distribution ,of an ,unset binder, Vwhere desired,

within the felt, the binder being set rin'later product linishingoperations. Y 3f The foregoing objectsY are attained by our? invention which resides, brieily stated; lin an apparatusand method involving a ber collectionchamber ortowerrtogwhich .adhesives;t

the fibers are delivered invan yairstrearn, libern opening means within thetower adjacent the entrance port -for the fibers, a liber collecting mean s,f-suitably` an airpervious conveyor, and means for suspending the-bers in an air current moving toward theconveyor. A zone of substantially zero static pressure is maintainedat and adjacent the surface of lthejconveyor whereby thekfeltingV takes place'without substantialyagitation vor compression..V

Means are provided for introducing a binder` in a finelydivided state, suitably arpowder'ed resin or 'thelike,` at i a convenient location prior tothe felting of the ib'er's Also, means' are provided for introducing, preferably byA spraying, an adhesive .materialflinto the suspension of bersfbefore felting, Vto impart handleability tof the felt j before the binder has been set. The apparatusand method are of particular advantage when used Withrelatively brittle'fibers, such as mineral wool ber's,or mixtures thereof with conventional textile'bers. t

Our invention will begmoreV fully-understood andffurther objects and advantages thereof`will becomef'ap, parent when referenceis madeto the moretdetailed de- Y scription o a preferred" embodiment ofthe invention which is to follow and to theraccompanying drawings in which:

section (see Figsi'ljand' 3). The lloorfoffthej-Yll k'chamber comprisingairendless conveyorl drivenfn j Y the direction indicatedfgbypthe arrovvbysuitablemeans v(not -show'n)l,}E Co`nveyori'16 is i of Wirefmesh-'or tether.

Y' j Apparatus may! be p'ovidedfof any A"suitable ype for Fig-(Z' sa ksectional view, taken on the linel--Zof j g Fig. 1'; and; 'l'

' Referring `novv` to theI drav'ving's;,-IfthereIy is s'hoyvn jaffeltandialov'ver sectionlilaring outwardly-fio the upp suitable openwork or""foraminous,-fair-perviousfconstmci '.v i Arduct 24 leads from sjor'nerl suitablev source of-fsupply lly 'opened' iibers, 'and;connects into-thegcollection chamber'10'-a`t the upper endfofpsectionfllzfjand `adjacent Aone offitsside f walls. v'Cooperatingcard`-ro11s26rdriveii1ingthe direc. y i tions indicated bythe arrowsare,locatedfwithin ther Vupper t section 1-2,`fi`theM "card`V` rollsfv closing :off `oflfthe cross-sectional areaof the `section ft'of the p ofthe bers,eiicept betvveenft -tially theireinainderfof thefarea 4 p -g v sage ,of fibers by a fcylinderfl ha mg a" peripheA alivall p i 1 Y'composed ofi wire mesh screeiill` perforated-irnetal, orV of other 'openworlr "construction-t1y The ycylinderv is riveir Fig. 1 is a diagrammatic, elevational view withsparts 'rality o'fsccessivefold laterally? onto'fa'fcont'inuously f` Y Thejdrive forfthef several' rolls, conveyors and other K niovin'gparts have otbeen shown;b'utfitiwill be ap- Y ypreciatc-:dj that these may-be ofsanyfconventional'ftype Ato; permit relative sr'veed"control lofthe `r"differentv operations; r gKV I .i

f. Means are I Y providedi `for earlier point inconduit The fibers employed-may befot anyconvenn efsuction box "beingcconnected :to:` the'eirhaust sideoffafblowerZO bylductfZZ.v 'I il 2o `portion ypplyin g Vboth binders andthejibersprior' otheirfcolleetionrp, The lbinderY appl ator may ffbe lajtd'ito vintroduce thek Ybinder t l i' 'r`i ,rt "thr collectinfvfthsbrs; and,`: as' illustrated; consists ,off. abinderjsupply 'Unef-.34 connected to any suitablesupplytnot 'shownJfof adify t powdered lbinder l'and i having Va delivery' end 1 zor nozzle t substantially at'the point Wherethe-bersfentertthe coll- 'lectonchambenf'todirect'the binder in @an airsteani onto f the fibers',asithey'passjtoFthe-rcardfrolls. However,'the binder rr'aybe introduce atanr Y i Z4`orbe1o`w` thevcardjrvlls,-` -,des`ired: Anadhesiv'e is preferablyapphed,tothe'libersf'n' addition ,to the binder, er 'Y `fand'fforfthispurposea'sprayheacl.36w onnected byfa liner 'dhesive supply' (notfishown) is ivvallfofl-the 'collection`rv chamber, "and substantiallyliabove' ther.floor'""tliiefereof,v and'is pointed in ai `directionfto v project 4a tine kspray .of adhesive into fthe and in carryingv'out the.z method ofthe f instant invention,V opened `or partiallyopenedaiibers: are carried by an 'airf streamgironi@ fsuitablejsupplythereof (not shown) through' duct 24, kand-1iny oduced finto theV collectionchamj l sect`ionf12`of=th collectionV and method are particularly adapted for the felting of relatively fragile, brittle fibers, such as mineral wool fibers, or such fibers intermixed with fibers of other types. As stated, the fibers introduced to the collection chamber have previously been cleaned and at least partially opened in any suitable way, the fiber cleaning and opening apparatus shown in our co-pending application, filed of even date herewith, being preferredfor this purpose.

The fibers entering the collection chamber are deposit ed onto card rolls 84 and carried therebetween for a final opening and fiber individualizing operation. The air entering with the fibers passes through the air-pervious walls of cylinder 28 and into the collection chamber.

The air iiows past and below the card rolls ata reduced velocity, due to the greater cross-sectional area of the collection chamber as compared to the conduit 24. The air current, decreasing in velocity as it approaches conveyor 16, because of the outward fiare of section 14, carries the fibers onto the conveyor. Blower 20 is operated by controlling its speed or the volume of air withdrawn by it in a manner such that suction is set up in suction box 13 to create a negative pressure of a value sufficient to only overcome the resistance tothe passage of air through the mass of fibers on the conveyor. in

this way a zone of practically zero static pressure is proi vided at and above the conveyor which performs several important functions. It eliminates the necessity of a seal roll at the exit port from the collection chamber as the air pressures inside and outside the chamber are substantially the same. Also, and of primary importance, `the felted web is not compressed or disturbed after it is formed and, hence, is of low-density and in a lofty state. Furthermore, very uniform felting is obtained.

Where the finished product is to contain a binder, the

binder material in an unset state, preferably a powdered resin, and either of a thermoplastic or thermosetting type, for example a resin such as urea-formaldehyde, phenolformaldehyde, or other resinous material is introduced to the fibers through line 34, the powdered material becoming intimately intermixed with the fibers as they pass between the carding rolls and fiow downwardly onto conveyor 16. In the preferred practice, an adhesive material is applied to the fibers whether or not a binder is to be employed, the adhesive having the function of adhering the fibers of the felt sufficiently to enable the lightweight felted web to be lapped and/ or subjected to other finishing operations prior to the setting of the binder. The adhesive, which should be a type that will effect cohesion of the fibers but not to be so sticky as to cause undue fouling of the chamber walls, is introduced through line 33 to sprayhead 36 and sprayed into the suspension of fibers as they pass to the conveyor. A preferred adhesive is a glycerine solution, for example, a 10% glycerine water solution.

Conveyor 16 may be driven at a slow speed to build up a layer thereon of the required thickness for the final product. However, it is usually found preferable to form a relatively thin, lofty felt on the conveyor and convert the same into a blanket of the desired thickness by a lapping operation. For this purpose the layer collected on conveyor 16 is transferred to the lapper conveyor and laid in successive folds transversely of conveyor 32. In either case, that is whether the layer is built up to the desired thickness on conveyor. .16, or whether it is lapped to provide a blanket of the desired thickness, the blanket may be subjected to any usual or conventional binder setting and other finishing operations to convert it into bonded batts or blankets, or into loose wool, modulated wool, and the like.

The above-described method and apparatus are versatile in operation and may be used with extremely brittle fibers without undue fiber breakage. They may be employed for the production of felts containing mixtures of fibers or fibers of different types may be successively handled. Irrespective of the type of lfibers employed,

the products obtained are lowin density, light in weight, lofty and of uniform structure.

Having thus described our invention in rather full detail, it will be understood that these details need not be strictly adhered to and that various changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.

What we claim is:

1. A method of collecting opened fibers comprising, delivering the fibers in an airstream to a collection cham# ber at a point above a collection zone thereof, introducing a finely-divided binding material to said fibers, subjecting said fibers and'binder to a fiber opening and binder distributing operation, discharging the opened fibers with` binder into an air current moving toward said collection zone to form a suspension therein, spraying an adhesive material into said suspension, and collecting the fibers from said suspension in interfelted relationship in said zone.

2. A method of collecting opened fibers comprising, delivering the fibers in an airstream to a collection chamber at a point above a collection zone thereof, introducing a finely-divided binding material to said fibers, subjecting said fibers and binder to a fiber opening and binder distributing operation, discharging the opened fibers with binder into an'air current moving toward said collection zone to form a suspension therein, spraying an adhesive meaterial into said suspension, maintaining substantially zero static pressure in said zone, and collecting the fibers from said suspension in interfelted relationship in said zone.

3. An apparatus for collecting opened fibers in ini terfelted relationship comprising, a collection chamber, fiber collecting means in said chamber, means for conducting an airstream carrying fibers therein to. the collection chamber at a point remote from said collection means, fiber opening means within said collection chamber in the path of the fibers carried in said airstream, means located above said opening means for introducing a binder to said fibers, and means for bypassing the airstream around said opening means while confining the fibers and binder to passage through said opening means.

4, An apparatus for collecting opened fibers in Vinterfelted relationship comprising, a collection chamv ber, an air-pervious floor in said chamber,v means for conducting an airstream carrying fibers therein to the collection chamber above said floor, fiber opening means within said collection chamber in the path of the fibers delivered in said airstream, means located above said opening means for introducing a binder to said fibers, means for lay-passing the airstream around said opening means while confining the fibers and binder to passage through said opening means, and suction meansv below said floor.

5. In apparatus for collecting opened bers in in-` terfelted relationship comprising, a collection chamber, fiber collecting means in the chamber, a conduit having an exit opening in said chamber at a point remote from said fiber collecting means,k card rolls within said collection chamber beneath said exit opening and closan ajr-pervious conveyor in the chamber forming the floor thereof, a conduit leading to said chamber and having an exit port in a wall thereof remote from said conveyor, fiber opening roll means between said port 1 and said conveyor, and means for withdrawing air through said conveyor.

.7. An apparatus particularly adapted for felting mineral wool bers comprising, a collection chamber, an air-pervious conveyor forming the iloor ofV said chamber, means for establishing a negative pressure-*beneath said floor, means for conducting an airstrearn carrying bers therein to the' collection chamber at the upper part thereof, ber opening rolls in said chamber in the path of bers delivered in the airstream, an air-pervious member adjacent said rolls obstructing passage of bers whereby fibers are caused to pass downwardly between said rolls, said member comprising a rotating perforated drum rotating toward the opening rolls.

8. Fiber collection meanscomprising a vertically extending tower, a ber inlet in the top of Ysaid tower, means for delivering ber through said inlet in an airstream, liber opening means positioned beneath said inlet and located in the upper portion of the tower, a foraminous conveyor positioned beneath said ber opening means and located at the bottom of the tower, and suction means for drawing air from the tower through the conveyor.

9. The apparatus of claim 8 including means for 1l. A method of collecting ber comprising carry- Y ing the ber substantially vertically downwardly through anY enclosed path, subjecting the fiber to an opening i p action'at an upper portion of said pathforming an'air from the suspension. y

introducing a powdered unset binder to said ber in a" region of the tower above said ber opening means.V

10. The apparatus of claim 9 including means for introducing an adhesive spray to said ber in a region of the tower below said ber opening means.

` troducinga powdered unset 12. The method 0f claimV 411 inciuding the Stepp of inthe opening l action.

13. The mezhdgof daim` 12 incldingihe stapler? introducingV an Vadhesive y, spray tol the ber subsequent tothe opening actionand while the Vvfiber: is( in suspension;

, i Referenes'Citedin/:thele of this. patentk i 1 Unirnn srArEs invrnrrrs*V l 't binder to the ber? prior to 

1. A METHOD OF COLLECTING OPENING FIBERS COMPRISING, DELIVERING THE FIBERS IN AN AIRSTREAM, TO A COLLECTION CHAMBER AT A POINT ABOVE A COLLECTION ZONE THEREOF, INTRODUCING A FINELY-DIVIDED BINDING MATERIAL TO SAID FIBERS, SUBJECTING SAID FIBERS AND BINDER TO A FIBER OPENING AND BINDER DISTRIBUTING OPERATION, DISCHARGING THE OPENED FIBERS WITH BINDER INTO AN AIR CURRENT MOVING TOWARD SAID COLLECTION ZONE TO FORM A SUSPENSION THEREIN, SPRAYING AN ADHESIVE MATERIAL INTO SAID SUSPENSION, AND COLLECTING THE FIBERS FROM SAID SUSPENSION IN INTERFELTED RELATIONSHIP IN SAID ZONE. 